Contact lens packages and methods of handling and manufacture

ABSTRACT

The present invention relates to improved contact lens packages and methods of use and manufacture/assembly. A contact lens package houses a contact lens and packaging solution and is configured to lift the contact lens out of the packaging solution when force is applied to a lever of the package and/or when the package is squeezed by the user.

I. CROSS REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit of U.S. ProvisionalApplication Nos. 63/243,525 filed Sep. 13, 2021; 63/124,835 filed Dec.13, 2020, 63/077,779 filed Sep. 14, 2020; and U.S. ProvisionalApplication No. 63/077,784 filed Sep. 14, 2020.

II. BACKGROUND OF THE INVENTION

In a conventional contact lens package, the contact lens typically sitsin a molded plastic base having a cavity (or “bowl”) that houses thecontact lens in a concave-side-up orientation. As a result, the userexperience for transferring a contact lens from the package to an eyegenerally involves the user “fishing” the contact lens out of the bowlwith a finger and then flipping the lens so that it is in the correctorientation on the finger for placement on the eye. This processrequires touching the lens multiple times, which can transfercontaminants or pathogens from the hand to the lens and ultimately tothe eye. Not only is this handling experience unsanitary, but it is alsounduly cumbersome, messy, and mechanically stressful to the lens, whichcan tear, rip, or distort when overly manipulated. While some packageshave been designed to present the lens in a convex-side-up orientationto obviate the need for flipping the lens, they often still require thelens to be “fished” from the packaging solution or otherwise necessitatemanipulation of the lens and/or multiple touches of the lens to achievetransfer of the lens to the eye.

In view of the growing awareness around ocular health and the customerdemand for a more convenient experience, a need has arisen for contactlens packaging that enables a less messy and more sanitary contact lenshandling process. In one respect, it would be ideal to provide wearersof contact lenses with a “single touch” package—that is, a packagewhereby the wearer of contact lenses can take the lens from the lensstorage package with a single touch of one of his or her fingers, andthen, with this single touch, position the lens correctly on the eye. Insuch a design, there would be no need for transfer and manipulation ofthe lens from one finger to another before placing the lens on the eye.Providing such a single touch package would not only streamline the lenspreparation and insertion process; it would also diminish thepossibility of dropping the lens or exposing the lens to additionalbacteria on a wearer's other fingers as the lens is being prepared fororientation and insertion onto the eye, and it also reduces thepossibility of touching the side of the lens which is intended tocontact the eye.

Design of a single touch lens package faces some distinct challenges.The wearer ideally should be able to consistently position the lens toadhere to the finger during removal from the package, and then the lensneeds to consistently release from the finger onto the eye. Contactlenses (of both the reusable and daily disposable variety) each has itsown unique surface, bulk, and geometric properties. Finger size and theforce a contact lens wearer imparts on the lens during transfer can alsovary. These factors can impact the process for taking the lens from thepackage onto the finger and then onto the surface of the eye. Amongother considerations: it would be desirable for wearers to be able todrain away any packaging solution which might impact the ability ofadhering the lens to the finger, as variation in the amount of packagingsolution adhering to the lens and package can impact the process ofplacing the lens on the finger. It would also be desirable for packagesolution to drain away in a controlled fashion that avoids spillage. Itwould also be beneficial for the packaging solution to remain sterileand accessible to the wearer after opening to permit re-wetting orcleansing of the lens. Also, the wearer may be concerned about thepotential of transferring bacteria or external products such as make upto the contact lens; and of course, manufacture of the package itselfshould conform to expected industry standards recognized by the medicaland commercial provider communities.

Further, the single touch package ideally should not result in aninordinate increase in the cost of goods over current contact lenspackages, as this could result in increased costs to the wearercommunity. The package should not make it difficult to hold the lenswhen removed from the package. Additionally, if the configuration of thepackage were to maintain, or even reduce the volume of solution neededto package the lens, this would reduce the ecological impact of the lenspackage. Similarly, it would be beneficial if all or part of the packagecould be made of recycled materials, and/or recyclable in whole or part.

In addition, it would be advantageous if the package were composed ofmaterials that are already approved by the various regulatory bodies andideally did not require a change in solution chemistry or lenscomposition. Optimally, as well, the functionality of the packagepreferably does not incorporate any electronics or other electricalcomponents if such components could adversely affect performance ofeither the package or the lens.

There are several desirable attributes that have made achieving thefunction of a single touch package challenging and that are oftenlacking in known attempts to create a single touch package. Theseattributes include, for example, the following: i) the package ideallyshould protect the lens, i.e., it should ensure the lens's integrity(e.g., lens shape and optical integrity), while at the same time preventcrushing or damage to the lens; ii) the lens package should maintain thehydration of the lens when stored to maintain the lens's properties; andiii) the lens in its package preferably should be configured so thatwhen desired, it is fully submerged in the packaging solution, yet becleared of such solution when ready to be transferred from thepackaging; iv) the package generally should have a retortable seal andcontain both the lens and solution; v) the package preferably shouldmaintain the lens in the desired convex orientation to the wearer; vi)the lens should be positioned so that it can be easily removed by thewearer; and vii) the package ideally should allow the packaging solutionto be effectively drained away from the lens upon opening of thepackaging and prior to lens removal to enable easier transferred to thewearer's finger and then onto the eye.

Known packages that have sought to provide reduce-touch or single touchorientations fail to provide one or more of the above-noted desiredattributes for a single-touch package. For example, WO2014/195588,WO2009/069265, JP6339322 disclose packages which present the lens in aconvex, bowl down configuration. However, the lens support structuressubstantially match the shape of the contact lens, which providesundesirable contact area between the lens and lens support. Thesereferences are also silent as to mechanisms for effective solutiondrainage from the lens and lens support.

Similarly, US20200229560 discloses packages with lens supports thatsupport the concave (anterior or front) surface of the contact lens, orgrates that support the contact lens peripheral edge and allowspackaging solution to drain through a grate to a bottom chamber uponopening the lens package. The foregoing noted deficiencies of the priorart are merely exemplary and not exhaustive.

Thus, there remains a need for contact lens packages which provide aconsistent single-touch lens removal experience, effective solutionmanagement, or addresses one or a combination of the aforementionedchallenges or deficiencies.

III. SUMMARY

It has now been found that some or all the foregoing and related objectsmay be attained in a contact lens package having one or more aspectsdescribed herein. For example, a contact lens package of the inventionmay house a contact lens and packaging solution wherein the package isconfigured to lift the contact lens out of the packaging solution whenthe package is squeezed by a user. The contact lens package may have alid and a base that includes a cavity that houses a contact lens andpackaging solution and a lever configured to hinge along a pivot line inthe base when a force is applied to the lever. The package may furtherinclude a lens support that intersects the pivot line such that forceapplied to the lever causes the lens support to lift the contact lensout of the packaging solution in a position on the lens support capableof single-touch transfer by a user. In some cases, the lever is adiscrete component that is coupled to the base by an attachment means.The pivot line may be defined by at least one void in the base and maybe imparted into the base by one or more of: a crease, a cut, a thinnedline, and an etch or the like. The base of the package may be composedof plastic and the lid may be a film. In some cases, the base and thelens support and/or the lever and lens support are a single unitarycomponent.

A lens support may be coupled to the base by i) a laser weld; ii) heat;iii) an ultrasonic weld; iv) an adhesive, or the like. The base mayinclude one or more finger engagement features configured to aid a userin grasping the package or direct the application of force such that thelever hinges downward. Possible figure engagement features includes aprotrusion in the base at a distal end of the package and/or an overhangalong at least a portion of the package's periphery. A dimple sized toaccommodate a finger or thumb of the user may be positioned at an end ofthe base proximal to the user. Finger engagement features may be pairedsuch that one is positioned at an end of the base proximal to the userand another is distal finger engagement feature positioned at an end ofthe base distal to the user. Alternatively, finger engagement featuresmay be positioned at any other opposed side or end of the package.

The lid of the package may include one or more lens facing surfaces thatextends downward into the cavity above the contact lens when the packageis in an unopened state. The lens facing surface and lens support may beconfigured within the cavity such that the optical zone of the contactlens is suspended in the packaging solution between the lens facingsurface and lens support when the package is in an unopened state. Thecavity of the package may house the contact lens in a convex positionwhen the package is in an unopened or opened state. And the lens supportmay have a profile that does not substantially match the contact lens'sprofile. When the package is an opened state, the wetted contact areabetween the lens support and the contact lens may be less than about 30mm², less than about 25 mm², or less than about 20 mm². The package mayinclude a lid insert having at least one alignment feature and/or one ormore lock-out features.

IV. BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the invention will beapparent from the following, more particular description of preferredembodiments of the invention, as illustrated in the accompanyingdrawings.

FIGS. 1A-D illustrate steps of opening a contact lens package accordingto an exemplary embodiment of the present invention.

FIG. 2 illustrates a perspective view of a contact lens package in anopened state according to an embodiment.

FIG. 3 illustrates an exploded perspective view of a contact lenspackage according to an embodiment.

FIG. 4 illustrates a close-up view of a lid insert in a cavity of anembodiment.

FIGS. 5A and 5B illustrate a cross-sectional view of a contact lenspackage in an unopened state according to an embodiment.

FIG. 6 illustrates air entry guides of a contact lens package accordingto an embodiment.

FIGS. 7A and 7B illustrate a lens support of an embodiment in a side andtop view, respectively.

FIGS. 8A and 8B illustrate a lens support of an alternative embodimentin a side and top view, respectively.

FIG. 9 illustrates contact lens packages of an embodiment in a nestedconfiguration.

FIG. 10 illustrates exemplary methods of manufacture of a contact lenspackage according to certain embodiments.

FIGS. 11-25 illustrate exemplary lens supports.

V. DETAILED DESCRIPTION

Reference will now be made in detail to representative embodimentsillustrated in the accompanying drawings wherein reference numeralsindicate certain elements. The following descriptions are not intendedto limit the myriad embodiments to one preferred embodiment.

To the contrary, it is intended to cover alternatives, modifications,and equivalents as can be included within the spirit and scope of thedescribed embodiments as defined by the appended claims.

References to “one embodiment,” “an embodiment,” “some embodiments,” “anexample embodiment,” etc., indicate that the embodiment described mayinclude a particular feature, structure, aspect, or characteristic, butevery embodiment may not necessarily include the particular feature,structure, or characteristic. Moreover, such phrases are not necessarilyreferring to the same embodiment. Further, when a particular feature,structure, aspect, or characteristic is described in connection with anembodiment, it is submitted that it is within the knowledge of oneskilled in the art to effect such feature, structure, or characteristicin connection with other embodiments whether or not explicitlydescribed.

As used herein, the following terms have the following meaning. Abenefit of the certain embodiments the present invention is that theyfacilitate consistent single-touch lens transfer from the package to awearer's finger, and then from the finger to the wearer's eye withoutthe lens inverting, falling off the finger or further manipulation.Consistent lens transfer includes a transfer rate of at least about 70%,at least about 80% or at least about 90% transfer on the first touch ofthe finger (or “dab”). The lens also desirably “sits up” on the fingerwithout collapsing or inverting and then transfers to the eye whenplaced there. Packages of certain embodiments may provide the desiredsingle-touch transfer across a range of finger sizes, and dab pressures.Environmental conditions such as the temperature and whether the fingeris wet or dry may also impact transfer rate, with higher temperaturesgenerally improving lens transfer.

Lens(es) or contact lens(es) refer to ophthalmic devices that reside onthe eye. They have a generally hemispheric shape and can provide opticalcorrection, cosmetic enhancement, UV blocking and visible light or glarereduction, therapeutic effect, including wound healing, delivery ofdrugs or neutraceuticals, diagnostic evaluation or monitoring, or anycombination thereof. The term lens includes soft hydrogel contactlenses, which are generally provided to the consumer in a package in thehydrated state, and have a relatively low moduli, which allows them toconform to the cornea. Contact lenses suitable for use with the packagesof the present invention include all hydrated contact lenses, includingconventional and silicone hydrogel contact lenses.

A hydrogel is a hydrated crosslinked polymeric system that containswater in an equilibrium state, and may contain at least about 25%, or atleast 35% water in the hydrated state. Hydrogels typically are oxygenpermeable and biocompatible, making them excellent materials forproducing contact lenses.

Conventional hydrogel contact lenses do not contain silicone containingcomponents, and generally have higher water content, lower oxygenpermeability, moduli, and shape memories than silicone hydrogels.Conventional hydrogels are prepared from monomeric mixturespredominantly containing hydrophilic monomers, such as 2-hydroxyethylmethacrylate (“HEMA”), N-vinyl pyrrolidone (“NVP”) or polyvinylalcohols. U.S. Pat. Nos. 4,495,313, 4,889,664 and 5,039,459 disclose theformation of conventional hydrogels. Conventional hydrogels may be ionicor non-ionic and include polymacon, etafilcon, nelfilcon, ocufilconlenefilcon and the like. The oxygen permeability of these conventionalhydrogel materials is typically below 20-30 barrers.

Silicon hydrogel formulations include balafilcon samfilcon, lotrafilconA and B, delfilcon, galyfilcon, senofilcon A, B and C, narafilcon,comfilcon, formofilcon, riofilcon, fanfilcon, stenfilcon, somofilcon,kalifilcon and the like. “Silicone hydrogels” refer to polymericnetworks made from at least one hydrophilic component and at least onesilicone-containing component. Silicone hydrogels may have moduli in therange of 60-200, 60-150 or 80-130 psi, water contents in the range of 20to 60%. Examples of silicone hydrogels include acquafilcon, asmofilcon,balafilcon, comfilcon, delefilcon, enfilcon, fanfilcon, formofilcon,galyfilcon, lotrafilcon, narafilcon, riofilcon, samfilcon, senofilcon,somofilcon, and stenfilcon, verofilcon, including all of their variants,as well as silicone hydrogels as prepared in U.S. Pat. Nos. 4,659,782,4,659,783, 5,244,981, 5,314,960, 5,331,067, 5,371,147, 5,998,498,6,087,415, 5,760,100, 5,776,999, 5,789,461, 5,849,811, 5,965,631,6,367,929, 6,822,016, 6,867,245, 6,943,203, 7,247,692, 7,249,848,7,553,880, 7,666,921, 7,786,185, 7,956,131, 8,022,158, 8,273,802,8,399,538, 8,470,906, 8,450,387, 8,487,058, 8,507,577, 8,637,621,8,703,891, 8,937,110, 8,937,111, 8,940,812, 9,056,878, 9,057,821,9,125,808, 9,140,825, 9156,934, 9,170,349, 9,244,196, 9,244,197,9,260,544, 9,297,928, 9,297,929 as well as WO 03/22321, WO 2008/061992,and US 2010/0048847. These patents are hereby incorporated by referencein their entireties. Silicone hydrogels may have higher shape memorythan conventional contact lenses.

Hydrogel lenses are viscoelastic materials. Contact lenses can formoptical distortions if the lens interacts with either the package or anyair bubble in the package. The extent of the optical distortions, andthe length of time needed for the distortions to relax out will varydepending on the chemistry, and to a lesser extent, geometry of thelens. Conventional lens materials, such as polyhydroxyethylmethacrylate-based lenses like etafilcon A or polymacon have low lossmodulus and tan delta compared to silicone hydrogels and may form fewerand less severe optical distortions as a result of contact withpackaging. The incorporation of silicones (which generally increase thebulk elastic response), wetting agents such as PVP (which generallyincrease the viscous response) or coatings of conventional hydrogelmaterials (which may lower the elastic response at the lens interface)can alter the lens viscoelastic properties. Conventional hydrogelcontact lenses and silicone hydrogel contact lenses having short orstiff crosslinking agents and or stiffening agent have short shapememories and may be less susceptible to deformation during storage. Asused herein, high or higher shape memory hydrogels display opticaldistortions from contact with an air bubble or package of at least about0.18 after 5 weeks of accelerated aging at 55° C. Viscoelasticproperties, including loss modulus and tan delta, can be measured usinga dynamic mechanical analysis.

The contact lenses can be of any geometry or power, and have a generallyhemispherical shape, with a concave posterior side which rests againstthe eye when in use and a convex anterior side which faces away from theeye and is contacted by the eyelid during blinking.

The center or apex of the lens is the center of the lens optic zone. Theoptic zone provides optical correction and may have a diameter betweenabout 7 mm and about 10 mm. The lens periphery or lens edge is the edgewhere the anterior and posterior sides meet.

The wetted lens is the contact lens and any residual packaging solutionattached to it after packaging solution drainage. Wetted contact is theaggregated contact area between the wetted lens and lens support.

Embodiments may include a lens support surrounded by a sealable cavityalso interchangeably referred to as a chamber. The cavity may have anyconvenient form and may comprise a package base and at least a lid, eachof which are described in detail below. As used herein, the phrases “thelid”, “a lid”, “the base” and “a base” encompass both the singular andplural. The lid and package base are sealed to each other to form acavity which holds the contact lens, support and packaging solution in asterile state during shipping and storage prior to use. The contact lenspackage is made from materials which are compatible with the contactlens and solution, as well as retortable and biologically inert.

“Film” or “multilayer film” are films used to seal the package and areoften referred to as lidstock. Multilayer films used in conventionalcontact lens packages may be used in the packages of the presentinvention as the base, a component of the lid, or both. Multilayer filmscomprise a plurality of layers, including barrier layers, including foillayers, or coatings, seal layers, which seal the film to the rest of thepackage, and may also comprise additional layers selected from peelinitiation layers, lamination layers, and layers that improve otherpackage properties like stiffness, temperature resistance, printability,puncture resistance, barrier resistance to water or oxygen and the like.The multilayer films form a steam sterilizable (retortable) seal. Themultilayer film can include PET, BON or OPP films layers to increasestiffness and temperature resistance, or to EVOH or PVDC coatings toimprove barrier resistance to oxygen or moisture vapor.

An “unopened state” or “unopened” as used herein refers to a contactlens package that is closed and houses a contact lens in solution.

An “opened state” or “opened” as used herein refers to a contact lenspackage after the sterile seal has been broken. Depending on the contextdescribed herein, the open state extends to the state of the packagewhen the user has manipulated the package to cause the lens to be liftedout of the packaging solution for transfer by the user.

A “wearer” or “user” as used herein refers to a person opening a contactlens package. The user is generally referred to as the person who bothopens the package and transfers the contact lens contained therein totheir eye. However, the user in some contexts may be a person handlingthe lens package on behalf of the wearer, such an eye care provider(“ECP”) or another individual demonstrating for or assisting the wearer.

Packaging solution is any physiologically compatible solution, which iscompatible with the selected lens material and packaging. Packagingsolutions include buffered solutions having a physiological pH, such asbuffered saline solutions. The packaging solution may contain knowncomponents, including buffers, pH and tonicity adjusting agents,lubricants, wetting agents, nutraceuticals, pharmaceuticals, in packagecoating components and the like.

The package base may form the bottom of the package. It can be made fromany material suitable for packaging medical devices, including plastic.The packaging lid generally resides at the upper portion the package andseals with the base to form a cavity containing at least a portion ofthe lens support, lens, and packaging solution. The lid may be made fromany material suitable for packaging medical devices, including a moldedsheet of foil or plastic, laminate films, or plastic. Packagescomprising plastic for one structure and foil or laminated films as theother, or packages comprising foil or laminated films as the outer layerfor the lid and base are known in the art and are examples of suitablecombinations.

References throughout this description to injection molding processesand the use of materials conventionally applied to injection moldingshould be understood as exemplary. Those of skill in the art willappreciate that other means of manufacture are possible within the scopeof the appended claims, including but not limited to alternative moldingprocesses, thermoforming, 3D printing, and the like. Likewise,references to heat seals and heat sealing are exemplary to embodimentsdescribed herein. Other means of securing packaging components will beapparent to those skilled in the art, including the use of adhesive,glue, thermal bonding, welding such as heat, ultrasonic or laserwelding, or a mechanical trap, and the like.

Certain aspects of the invention may serve to reduce or preventsignificant optical damage to the contact lens due to interactions withair bubbles or the interior of the lens package that may arise duringstorage or transit due to gravitational or other forces, such asmechanical pressure being applied from outside of the package. As usedherein, significant optical damage means a root-mean-squared (RMS) valueequal or greater than about 0.08 μm.

With reference to the figures, FIGS. 1A-1D illustrate steps of handlinga contact lens package containing a contact lens in packaging solutionaccording to an exemplary embodiment of the present invention. Anunopened contact lens package 100 having a lid 106 and a base 110 isshown at FIG. 1A. In this embodiment, the lid 106 is a multilayer film,also referred to herein as the foil, and the base 110 is composed of athermoplastic polymer, such as polypropylene plastic. While in thisembodiment the lid 106 takes the form of a relatively flexible material(i.e., multilayer film) and the base 110 a relatively rigid material, itshould be appreciated that other embodiments may include substantiallyrigid components for both the lid and the base. For example, in someembodiments, the base and lid both could be composed of a polypropyleneplastic or other relatively rigid material. Base 110 includes a pivotline 114 along which a portion of the base that forms a lever 118 canhinge when force is applied to the lever 118.

Base 110 further includes several optional finger engagement features122 a-122 c to assist the user with handling the contact lens packageduring the opening process. A finger dimple 122 a may be sized toaccommodate a finger or thumb of the user is disposed at the end of thebase 110 proximal to the user; an overhang 122 b along a peripheral edgeof the base 110; and a protrusion 122 c is disposed at the end ofpackage 118 distal to the user. Finger dimple 122 a in this embodimentis also angled downward such that a force, e.g., pressure applied by athumb of the user, causes the lever 118 to hinge downward at the pivotline 114. Package 100 in this embodiment is further configured with aprofile that slopes from proximal to distal end to further encourage adownward moment at the lever, for example when the lever is pressed downor the when the package is squeezed by the user, i.e., when the userapplies pressure by hand at opposing ends of the package, i.e., via afinger at one end and a thumb at the other. In this embodiment, package100 is configured such that the squeezing forces are applied at thedistal and proximal ends. However, alternative embodiments are possiblewhereby the opposing forces involved in squeezing are applied atalternative opposing ends of the package, such as but not limited to thesides, left and right, of the package.

In a first step shown in FIG. 1B, a user holds an unopened contact lenspackage 100 by its base 110. As illustrated, a user's grip upon thepackage 100 may be improved by one or more finger engagement features122 a-c positioned and configured to provide a more secure grasp uponthe package and/or to aid in the application of force that, in a laterstep, causes a contact lens contained in the package to be lifted forpresentation to the user and transfer to the user's eye. Finger dimple106 is positioned on lever 118 of base 110 and is sized for a thumb 126of the user to grip the package. At the opposite end of package 100, theuser may grasp the package as shown by positioning a finger securelyunder an overhang 122 b and against a protrusion 122 c at the end of thebase 110. In the case of an overhang, the overhanging region may becurved or may be flattened to provide an increased area across which anopposing force can be supplied when the package is squeezed. Next, theuser may open the package by opening the lid 106, which in thisembodiment involves the user peeling open the foil 106 from the proximalend of the base 110 to the distal end in the direction shown by arrow134, thus breaking a sterile seal between the foil (lid) 106 and base110. Although not required, in this preferred embodiment the package isoptimized for the user to grasp the base with one hand and peel open thelid 106 with the other hand.

As illustrated at step shown in FIG. 1C, the package lid 106 has beenopened, either by complete removal of the lid as shown in theillustration or, alternatively, by partial removal sufficient tosubstantially expose lens cavity 136, which houses a contact lens 138suspended in packaging solution (not illustrated) above a lens support140. With the package 100 open, the user then applies a force 142 tolever 118. In this embodiment, the package is configured to be squeezedby the user whereby the user's hand or hands supply opposing forces 142and 146 at the proximal and distal ends of the package, respectfully,thereby generating a more significant force upon lever 118.

Turning to FIG. 1D, the force applied to the lever by the user causesthe lens support 140 to lift the contact lens 138 out of the packagingsolution (not illustrated). Ideally, a lens support is configured tolift a contact lens high enough above the package cavity that the lensis facing the user, and is thus visible and transferable from thesupport, but not so high that the lens slides off the support under theforce of gravity. This may be accomplished by an angle of lift ofbetween about 15° to 60° relative to the horizontal plane that definesthe top of the base when force is applied by the user. A lens supportpreferably is configured so that, when lifted in this manner, packagingsolution drains away from the contact lens sufficiently to enablesingle-touch transfer by the user, as in the exemplary the embodimentillustrated where the user transfers the contact lens 138 from the lenssupport 140 by tapping (also referred interchangeably as “dabbing”) aconvex surface of the contact lens 138 such that the tapping causes thecontact lens to release from the lens support 138 and adhere to a finger154 of the user.

In this embodiment, contact lens 138 conveniently is presented to thewearer in a convex orientation, meaning that convex side of the lens 138is accessible to the wearer without the need to reorient the lens beforeplacing the concave side of the lens onto the wearer's eye surface. Itwill be appreciated however that other orientations, such as the concaveorientation of traditional blister packages, are possible within thescope of invention. Transfer of the contact lens 138 from the lenssupport 140 may be performed by a wearer's finger 154, either directlytouching the lens or indirectly by way of an applicator film (e.g., asdescribed in US20190046353) or other covering applied to the finger, ormay be performed by another transfer means, such as a manual orautomatic applicator device or tool. Upon transfer of the contact lens138 from the package 100, the lens rests on the finger 154 (or othertransfer means), as shown in step illustrated, with the convex side ofcontact lens 138 against the finger 154 and the concave side of the lens138 oriented for direct application to the user's eye surface.

Turning now to FIGS. 2 and 3 , FIG. 2 illustrates a perspective view ofcontact lens package 100 in an opened state in which lens support 140has lifted contact lens 138 out of the packaging solution (notillustrated). FIG. 3 illustrates an exploded perspective view of contactlens package 100. Contact lens package 100 includes base 110 that has aproximal end (A) and distal end (B). At its distal end (B), base 110includes a cavity 136 that houses a contact lens 138 in packagingsolution and a lever 118 configured to hinge along a pivot line 114 inthe base when a force is applied to lever 118. In this embodiment, lever118 is formed as a portion of a unitary component that composes the base118. More specifically, base 110, including lever 118, is formed as aunitary injection-molded polypropylene plastic part. Alternativematerials and processes for forming the base will be appreciated bythose skilled in the art, including thermoforming and 3D printing (usingmaterials such ABS, PLA, HIPS, PETG, Nylon, or others). Preferably, thematerial used for the base is relatively rigid, having a glasstransition temperature (T_(g)) of about 125C as measured in accordancewith ASTM D1238-10 (Standard Test method for Melt Flow Rates ofThermoplastics by Extrusion Plastometer). In this embodiment, pivot line114 is defined by multiple voids 158 in the base. Voids 158 arepositioned in a linear configuration along a horizontal axis at a pointalong which it lever 118 hinges. The absence of material that createsvoids 158 provides sufficient relief along a line in the base materialto cause lever 118 to hinge at the desired position when force isapplied to the lever by a user. The distance of the lifting arm, i.e.,the distance from the pivot line to the center of the contact lens whenresting on the support is between about 10-12 mm, and preferably between12-17 mm. The use of one or more voids is merely one of myriad ways thata pivot line may be defined within the scope of the invention. Forexample, in other embodiments in which the lever is formed in the samematerial as the remainder of the base, the pivot line may be created bycreasing the plastic laterally at the desired location by molding thematerial to be thinner along the pivot line, and/or by cutting, etchingor otherwise imparting a pivot line into the base material. Furthermore,in embodiments in which the lever takes the form of a discretecomponent, the pivot line may merely represent the horizontal interfacebetween the lever and remainder of the base. In such embodiments,hinging along the pivot line may be effected by a hinge component, arotatable interlocking attachment, or the like. It should be appreciatedthat alternative embodiments are possible within the scope of theinvention in which the lever is a discrete component coupled to theremainder of the base by an attachment means. For example, a lever maybe formed as a separate injection molded part and then attached to aseparately molded (or printed, etc.) part that forms the rest of thebase via an array of attachment means, including laser welding,ultrasonic welding, adhesive, mechanical attachment, heat staking, orthe like.

The underside of the base may be sloped, as in the embodimentillustrated, to enable the packages to “nest” thereby allowing morecompact secondary packaging during storage and transport (as describedfurther with reference to FIG. 9 ) in addition to reducing the amount ofprimary packaging material and packaging solution necessary to keep thecontact lens hydrated. In this example, base 110 slopes from theproximal end (A) to distal end (B) at an angle of approximately 14° andhas a footprint of approximately 29 mm in width, 44 mm in length, and9.5 mm in height. Preferred slopes have a range of between about 10-20°,but the slope may be made even steeper, e.g., about 20-30°, as desired.The base includes a well, i.e., cavity 136, formed in the tapered areain which the contact lens 138 and lens support 140 are housed whenpackage 100 is unopened. In this embodiment, the cavity has a volume ofapproximately 2240 μl which is dosed with approximately 2080 μL ofpackaging solution, which is sufficient to fully submerge the contactlens 138 within the cavity 136. The foil lid 106 is secured to the base110 via a retortable seal formed between bead 152 on the upper surfaceof the base around the perimeter of the cavity 136. This seal may beformed by well-known heat-sealing techniques and associated apparatuses.

Finger engagement feature (dimple) 122 a is sized to accommodate afinger or thumb of the user is disposed at the end of the base 110proximal to the user. Finger dimple 122 a in this embodiment is alsoangled downward such that a force, e.g., pressure applied by a thumb ofthe user, causes the lever 118 to hinge downward at the pivot line 114.The position of the finger dimple position of this dimple and the fingerof the user relative to the pivot line affects the amount of squeezeforce necessary to cause the lever to hinge along the pivot line. Inthis example, the dimple depth below the pivot line is 4.5 mm whenmeasured from the seal level to the base of the dimple.

A lens support 140 is coupled to the lever 118 so that force applied tothe lever 118 causes the lens support 140 to lift the contact lens 138out of the packaging solution. In the embodiment illustrated, lenssupport 140 is a separately molded (or printed) component that isfixedly attached to the lever 118 portion of the base. Attachment ismade here via a stake 162 formed in the lever portion of the basematerial. Lens support 140 has an opening 166 corresponding to the stake162 so that, when lens support 140 is placed onto the base, stake 162mates with opening 166. Heat is applied using a hot plate to thestake/opening to deform the plastic material using heat and force,holding the stake securely in position like a rivet. A bond is made bypartially deforming the stake 162 around opening 166. Numerous othermeans of attachment other than heat staking are possible within thescope of the claims, including e.g., laser welding, ultrasonic welding,adhesion, mechanical clipping, and the like. Further, it should be notedthat in alternative embodiments in which the lens support may be formedas part of the same unitary molded or printed component as the leverand/or the entire base. The point of coupling/attachment of the lenssupport to the lever is preferably about 2 to 5 mm from the pivot lineto the front of the peg/stake. In many embodiments, such as the oneillustrated in which the pivot line is formed by a fold in plastic orother substantially rigid material, the pivot line may have a thickness,i.e., it may not be perfectly sharp. In these cases, such separation maybe needed between the point of attachment and the pivot line in order tomaximize the lifting angle for a given bend force.

The underside of a lid 106, as can be seen in FIG. 2 ., includesmultiple lens facing surfaces 168, which in this embodiment are formedas projections extending downward toward the lens's convex surface. Thelens facing surfaces 168 are generally shaped to mirror the convex lenssurface of the contact lens to be housed in the lid cavity 136. The lensfacing surfaces 168 serve to align the contact lens over the lenssupport and to protect the contact lens against significant opticaldamage due to gravitational or air-induced forces. In some embodiments,lens facing surfaces also serve as air entry guides by guiding airentering the package over the contact lens to reduce the incidence ofthe contact lens sticking to the package upon opening. In this case, thelens facing surfaces are provided on a molded plastic lid insert 170,wherein the lid insert 170 is attached to an inner surface of the foillid 106 by a heat seal. But in other embodiments, for example where thelid is substantially rigid, the lens facing surfaces may be integral tothe lid rather than a separate component. It will be understood that allfeatures described as being imparted upon a lid insert could be appliedequally to embodiments in which the same features are made integral tothe lid.

Lens facing surfaces of the present invention serve to support the lenswhen loaded by these forces to avoid or reduce significant opticaldamage. For example, gravitational forces and interactions with airbubbles in the packaging solution can result in optical damage if notproperly counteracted. In one aspect, lens facing surfaces, as in thelens facing surfaces 168 of the illustrated embodiment, include arelatively large contactable surface area, at least about 3 percent andpreferably at least about 20% of percent or as large as possible whilestill accommodating any desired air egress channels. The contactablesurface area is understood to mean the area of contact between the lensand lens facing surfaces when the lens is loaded, i.e., placed intocontact under an applied force, such as but not limited to gravity orair bubble interaction. The contactable surface area determines thepressure exerted on regions of the lens when/if it is loaded. The largerthe area, the more the pressure is reduced. In the embodimentillustrated, the lens facing surfaces 168 have a contactable surfacearea of 100 mm² conventional contact lens having a surface area ofapproximately 215 mm². As discussed in more detail below, it ispreferable that at least 10% of the surface area above the lens be leftexposed to promote air entering the package to travel over to reduce anytendency of the lens to stick to the lens facing surfaces/lid insert.

The lens facing surfaces 168 are also spaced apart to define air egresschannels 169 allow air, in particular air bubbles in the packagingsolution, to travel away from the contact lens into a peripheral volumeof the cavity 136. It is advantageous for the air egress channels have apositive gradient toward the peripheral volume with a vertical rise ofat least about 2 mm. Air egress channels permit smaller air bubbles toescape from the area around the lens surface while simultaneouslyavoiding larger bubbles entering the space above the lens. Toward thisend, preferred embodiments include at least two air egress channels eachhaving a width of between about 1 mm-1.5 mm or preferably between 1.5mm-2 mm and, specifically 1.5 mm in the embodiment illustrated. In arelated aspect, air egress channels 169 advantageously form an “X”configuration. This configuration of air egress channel positionsrelative to each other allows, when the package is rotated in a sideorientation, at least one of the channels always to have a central axisfrom near the center of the cavity that is angled relative a planenormal to gravity. This aspect exploits buoyancy to allow air bubbles toescape away from lens irrespective of the orientation the lens packagetake thus reducing the optical damage that might otherwise result, e.g.,from the air bubble forcing the lens into the lens support.

Lid insert 170 is attached to an inner surface of the lid 106 in thisembodiment by a heat seal between the multilayer film lid 106 and theplanar surfaces 172 a-d on the upper side of the lid insert. Asdiscussed in more detail later herein, alignment of a lid insert withthe base during the heat-sealing process and during storage may be aidedby the inclusion of one or more alignment features in the base and/orlid insert. For example, alignment features 174 in the embodimentillustrated take the form of columns on the interior wall of cavity 136of the base 110. The alignment features 174 resist rotation and lateralmotion of the lid insert 170 when pressure is applied to seal thepackage 100 or during normal use. Alternative alignment features arepossible such as but not limited to forming the cavity and lid insert(or integral portion of the lid comprising lens facing surfaces) in anon-circular shape such that the components interlock and resistrotation inherently.

Referring now to FIG. 4 , illustrated is a close-up view of a lid insert170 when inserted in cavity 132 of base 110. The position of alignmentfeatures (e.g., columns 174) on the wall of cavity 136 of the base 110correspond to openings 178 in lid insert 170. Columns 174 and openings178 cooperate as an assembly to restrict rotational and lateral movementof the lid insert 170. In another aspect, the lid insert may beconfigured to prevent the lens support from lifting (other than theexpected time during opening) and to ensure that the lens is notcompressed in the package due to external forces when sealing pressureis applied or during storage, transport, or when the user opens thepackage. For example, a lock-out feature may be included to prevent lidfeatures, such as lens facing surfaces (whether integral to the lid orincluded on a lid insert) from impinging on the lens when pressure isapplied overhead, such as when the lid is sealed to the base or when thelid insert, if any, is sealed to the lid. Other lock-out features may beincluded to stop the lens support from impinging into the lens (e.g. dueto bending the pack at the pivot before it is open) by making a point ofcontact between the lens support and the lid insert. Further still,another lock-out feature in this embodiment is created by a ledge 180along the perimeter of the floor of cavity 136. One function of theledge 180 is to avoid a pinch point for the lens perimeter duringassembly. The height of the ledge above the cavity floor is madesufficient so that the lid insert and/or lens facing features of the lidare stopped at a height above where the lens is housed beneath. In thisembodiment, the ledge measures approximately 0.8 mm in height above thebase of the lens. It should be understood that a ledge is yet anotherexemplary lockout feature of many possibilities. To be sure, the lidinsert could be locked out at any level (e.g. level with the base of thelens, level with the top of the pack).

FIGS. 5A and 5B illustrate a cross-sectional view of a contact lenspackage 100 in an unopened state. Specifically, FIG. 5B illustrates thecross-section created across section plane AA indicated in theperspective side view in FIG. 5A. As shown, package 100 is configuredsuch that when in an unopened state, contact lens 138 is substantiallysuspended between lens support 140 and lens facing surfaces 168.Packages of the invention preferably minimize contact with the contactlens when the package is closed, and the lens is suspended in packagingsolution. Ideally, the optical zone of the lens is free floating andcontact with the lens support during storage is transitory ornon-existent. Depending on the buoyancy of the lens in the packagesolution and the orientation, the lens may rest on its peripheral edgeon the floor of the cavity in the base of the package or on its convexsurface on the lens facing surfaces. As illustrated, contact lenspackage 100 is in a lid-up orientation in which the peripheral edge ofthe contact lens rests on the floor of the cavity 136 in the base 110.However, the optical zone of the contact lens 138 is effectivelysuspended between the lens support 140 and the lens facing surfaces 168.

Cavity 132 preferably is substantially filled with packaging solution,provided however that manufacturing processes may not permit sealing thepackaging under vacuum pressure. In such cases, it is anticipated thatsome amount of air will become entrapped in the cavity. If these airbubbles are not managed, they may interact with the lens and causesignificant optical damage to the lens. Accordingly, peripheral volumesin the cavity, i.e., volumes in the cavity that are peripheral to thelocation of the lens over the lens support, may be provided. Ideally,such volumes should be provided at the distal and proximal ends of thepackage, such as 132′ and 132″ of cavity 132 of package 100, so that theair bubbles have a place to reside regardless of the orientation of thepackage during transport or storage.

In one aspect, lens facing surfaces may function as air entry guidesthrough placement and configuration that causes air that enters thepackage upon opening to travel over the contact lens to avoid thecontact lens sticking to the lid or lens facing surfaces thereof. Asillustrated in FIG. 6 , contact lens package 100 is depicted in anassembled, unopened state in which the foil lid is not shown so that thecomponents as sited within package 100 may be seen in this embodiment,the package 100 is configured to be opened from proximal end (A) todistal end (B) such that air enters the package in the directionindicated by arrow 190. To ensure that air travels over the lens, lidinsert 170 is configured so that the convex surface of the lens 138 isexposed above the lens edge closest to the point 192 that air enters thecavity upon opening. This may be achieved by positioning the lens facingsurfaces predominantly over the lateral and distal surface areas of thecontact lens and leaving exposed at least about 10% the surface area ofthe contact lens nearest point 192 where air enters the cavity. Morespecifically, in this embodiment, 15% of the contact lens's surface areais left exposed.

Lens supports of the present invention may take myriad shapes and formscapable of lifting the lens out of the packaging solution when the userapplies force(s) to the package, such as squeezing the package asdescribed with respect to embodiments herein. However, as mentioned itis preferable that the lens support keeps the lens in the desired convexorientation (bowl down relative to the base) and position (centered overthe support) during shipping and storage. Ideally, the lens support mayprovide an open structure under the lens to allow, upon opening, thepackaging solution to drain from the lens and support without trappingwater between the support and the underside of the lens. It is alsopreferable that the lens support has a sufficient number of contactpoints with the lens to prevent the lens from collapsing onto, rotatingoff or translating across the support. This allows the apex of the lensto be supported by the lens's own elastic stiffness, or to minimizesinking of the lens apex while limiting the contact area between thesupport and lens. Too much contact between the support and the lensafter solution draining, and water trapped between the support and thelens, can create surface tension between the lens and water on andaround the lens support that is greater than the surface tension betweena wearer's finger and the lens, interfering with efficient lenstransfer.

The sum of the contact between the lens and the lens support when thepackage is open, and the solution drained from the lens and lens supportis the total wetted contact area, which may be less than about 30 mm²,less than 25 mm² or less than 20 mm² and is distributed at least aroundthe lens periphery, as described herein. “Wetted contact area” as usedherein refers to the direct solid contact area between the lens supportand the lens added to the area of any menisci, reservoirs, or solutionbridges that form between the lens and lens after the lens is lifted andpackaging solution is allowed to drain for less than about <30 s, lessthan about <5 s, or less than about 2 s, depending on the intended userexperience of the package.

For lenses made from polymers with longer shape memory, the lens supportmay be designed to limit contact between the lens and support duringstorage. Such contact may be distributed around the lens peripheraledge. Contact between the lens optic zone, lens support and lid interior(including any air entry guides) may be transitory or there may be nocontact between the optic zone and support, lid or air entry guides.Lenses, such as conventional hydrogels, having shorter shape memory, areless prone to distortion from packaging contact, and can have thecontact points distributed around the periphery and throughout the lensprofile, including the lens center zone (about 9 mm, or about 5 mmdiameter).

The lens supports of the present invention preferably allow, upondabbing, both the fingertip and lens to deform to match each other'sshape, without causing lens inversion or damage to lens during removalfrom too much pressure during dabbing. Thus, an aspect of the removal ofthe lens from the present packages may be to control the ratio of thecontact area between the finger and lens as compared to the area betweenthe lens and the lens support so that the contact area between thefinger and lens exceeds the contact surface area of the lens support onthe lens underside. This will ensure that surface tension between fingerand lens exceeds surface tension between lens and lens support. Thus,the lens will adhere to the finger for lens transfer and placement ontothe eye.

The lens support preferably provides at least 2, at least 3, 3 to 14, 4to 14, 3 to 8 or 4 to 8, 4 to 6 or 6 points of contact with the contactlens edge along the peripheral supports. When two peripheral supportsare used, they may be wider to provide stability, without exceeding thearea of contact desired for consistent lens transfer. The peripheralpoints of contact prevent the lens from rotating off the lens and can bedistributed in a number of configurations, in which the space betweenthe furthest adjacent contacts is less than the diameter of the lens. Asthe number of peripheral supports is increased the likelihood ofresidual packaging solution forming films between adjacent peripheralsupports and solution bridging between the support and lens may beincreased during drainage. Peripheral supports with less than 50% openspace such as those in the form of a screen or strainer, generallyprovide insufficient drainage to insure one touch transfer. Likewise,too much contact between the support and the lens after solutiondraining, and water trapped between the support and the lens, can createsurface tension between the lens and water on and around the lenssupport that is greater than the surface tension between a wearer'sfinger and the lens, interfering with efficient lens transfer. The widthof the constituent support members of the lens support vary between thelimits of the selected molding process and widths necessary forefficient packaging solution drainage upon opening. Suitable widthsinclude about 0.5 to about 1.5 mm, about 0.5 to about 1, or about 0.5 toabout 0.7 mm, and it will be appreciated that lens support designshaving fewer contact points may have thicker arms.

Lens supports may achieve sufficient drainage of packaging solution fromthe lens to enable single-touch transfer through one or a combination ofdrainage techniques referred to herein as channel drainage and backdrainage. Channel drainage involves the formation on the lens support ofchannel members along which packaging solution is channeled away fromthe lens under the force of gravity when the lens support is lifted.Back drainage, on the other hand, refers to enhanced drainage from theunderside of the lens where the lens rests on the lens support. Thisarea underneath the apex of the lens tends to trap packaging solutiondue to the hydrophilicity of modern contact lens materials. Enhancedback drainage may be achieved in some embodiments by designing the lenssupport with a central opening beneath the apex of the lens of at leastabout 12 mm³.

Referring then to FIGS. 7A and 7B, illustrated is exemplary lens support140 in a side and a top view, respectively. Lens support 140 representsan example of a lens support that leverages a hybrid of back drainageand channel drainage to clear packaging solution from the lenssufficiently to enable single-touch transfer. Lens support 140 includesa central support composed of three central support members 200 a-c in asemi-circular configuration having a diameter of approximately 8 mm.Central support members 200 a-c are elevated 2.5 mm by pillars 204.Pillars 204 extend upward from channel members 204 a and 204 b, whichtransition along their length from proximal end (A) to distal end (B) toform a channel formation into a peripheral support 208. These memberscooperate so that when the contact lens is lifted from the package, itrests upon lens support 240 in the preferred convex orientation (bowldown relative to the base of the package) at 7 contact points when thelens is lifted from the packaging solution.

The design of lens support 140 creates central opening 212 to allow thepackaging solution to back drain from the lens and lens support 140 whenthe package is opened and the lens support lifted from the packagingsolution. This allows the apex of the lens to be supported by the lens'sown elastic stiffness, and to minimize sinking of the lens apex whilelimiting the contact area between the support 140 and lens. The designalso provides sufficient support to edge of the contact less at pointsalong the channel members 204 a and 204 b as well as along peripheralsupport 208. This configuration sufficiently reduces the wetted contactarea between the lens support 140 and the contact lens to at least about25 mm² when measured 2 seconds after lens support 140 is lifted.

One of myriad alternative embodiments of a lens support within the scopeof the invention is shown at FIGS. 8A and 8B illustrate in a side and atop view, respectively. Lens support 300 represents an example of a lenssupport that relies upon back drainage to clear packaging solution fromthe lens sufficiently to enable single-touch transfer. Lens support 300includes a central support 310 composed of four equally spaced radialspokes extending across a diameter of approximately 10.5 mm. Centralsupport members 310 is elevated 2.7 mm by pillars 314. Pillars 314extend upward from support member 318, which includes a tab 324 by whichthe lens support 300 may be coupled to a base of a contact lens packagein certain embodiments of the invention. Peripheral support members 328and 330 are formed in a continuous bow-tie configuration to providesupport to the edges of a contact lens when the lens is lifted from thepackage and resting upon the support. The central and peripheral supportmembers of support 300 cooperate so that when the contact lens is liftedfrom the package, it rests upon lens support 300 in the preferred convexorientation (bowl down relative to the base of the package) at 5 contactpoints when the lens is lifted from the packaging solution.

The design of lens support 300 includes sufficient open space betweenthe spokes of central support 310 to allow the packaging solution toback drain from the lens and lens support 140 when the package is openedand the lens support lifted from the packaging solution. This allows theapex of the lens to be supported by the lens's own elastic stiffness,and to minimize sinking of the lens apex while limiting the contact areabetween the support 300 and lens. The design also provides sufficientsupport to the edge of the contact lens at points along the peripheralsupport members 328 and 330. This configuration sufficiently reduces thewetted contact area between the lens support 300 and the contact lens toat least about 25 mm² when measured 2 seconds after lens support 300 islifted. It must be emphasized that the lens support embodimentsillustrated and described herein are merely two among of myriadembodiments of a lens support within the scope of the invention as setforth in the appended claims. To be sure, a number of additionalillustrative but non-limiting exemplary lens supports are depicted inFIGS. 11-25 .

As noted above, in one aspect contact lens packages of the presentinvention may be configured to allow a nested configuration. FIG. 9illustrates two of contact lens package 100 shown as packages 100′ and100″ in a nested configuration. A nested configuration, such as the onedepicted in which the packages fit together securely within a smallervolume are useful for reducing the amount of secondary packaging (e.g.,carton or other container in which the primary packages are provided tothe consumer). In this embodiment, packages 100′ and 100′ are designedto nest when arranged base-to-base and inverted relative to each otherfrom proximal end to distal end. The ability of contact lens packages100′ and 100″ to nest is enabled by a combination of features including:a taper in the base 110′ and 110″ of each package and finger engagementfeatures (dimples) 122 a′ and 122 a″ functioning as stops againstlateral movement of the bases 110′ and 110″.

Turning now to FIG. 10 are illustrated exemplary methods ofmanufacture/assembly of a contact lens package in accordance with anembodiment. A first exemplary method of manufacture/assembly of theexemplary contact lens package 100 is illustrated as steps 1001A, 1002A,1003A, 1004A, and 1005. At a first step 1001A, a contact lens 138 isplaced onto lens support 140 in this embodiment with the contact lensbeing placed onto the lens support 140 with its concave side of thecontact lens onto the lens support. The lens support may be pre-dosedwith packaging solution sufficient to cause the contact lens to bind tothe support. In a slightly alternative approach not illustrated, thelens support may be inserted into the cavity first and the contact lensplaced on the support thereafter. At a next step 1002A, lens support 140with the contact lens 130 resting thereon is inserted into cavity 136 ofa base 110. Then, at step 1003, lid insert 170 comprising lens facingsurfaces 168 is placed onto the convex side of the contact lens 138.Next, at step 1003A, the cavity is dosed with packaging solutionsufficiently to fully submerge contact lens 138 in the cavity andideally as full as possible without overflowing the cavity. Preferably,at least one of the fitment and/or a surface feature of the lid insertagainst the base cavity creates a friction fit so that the lid insertdoes not float out of position when the packing solution is added to thecavity. Finally, at a step 1005, the lid 106 is sealed onto the base110, for example by heat sealing the foil to the base as described inmore detail above, such that the sealing encloses the contact lens 138and packaging solution within the cavity 136 in a sterile environment.

An alternative exemplary method of manufacture/assembly of the exemplarycontact lens package 100 is illustrated as steps 1001B, 1002B, 1003B,1004B, and 1005. At a first step 1001B, a package base 110 is providedwherein a cavity 136 of the base 110 has lens support 140 coupledthereto. In this example, lens support 140 is coupled to the base by aheat staking process as described in more detail above. However, asnoted, other means of attachment are possible within the scope of theclaims, including e.g., laser welding, ultrasonic welding, adhesion,mechanical clipping, and the like. Next at a step 1002B, a contact lens138 is placed onto a lens facing surface of a lid insert 170, in thisembodiment with the lens's convex surface resting against the lensfacing surfaces 168 of lid insert 170. The lens 138 may be placed ontothe lid insert by manual or automated means such as through a lenstransfer nozzle. Then, at a step 1003B, the lid insert 170 having thecontact lens 138 resting thereon is placed onto the lens support 140 inthe cavity 136 of the base 110. Next, at a step 1004B, the cavity 136 isdosed with packaging solution sufficiently to fully submerge the contactlens 138 in the 136 cavity and ideally as full as possible withoutoverflowing the cavity. Finally, at a step 1005, the lid 106 is sealedonto the base 110, for example by heat sealing the foil to the base asdescribed in more detail above, such that the sealing encloses thecontact lens 138 and packaging solution within the cavity 136 in asterile environment.

In some methods of manufacture/assembly of contact lens packages withinthe scope of the invention, the provision of packaging solution to thecavity may take place in multiple doses at different steps of theassembly process as opposed to all at once as described in the exemplarymethods above. For example, in embodiments in which the lens is placedupon the lens support (e.g., step 1001A above) it may be advantageous topre-dose a small amount of packaging solution onto lens support beforeresting the lens thereon so that the lens becomes secured to the lensunder the surface tension of the solution. Dividing the dosing ofpackaging solution may also be advantageous when filling the cavity,such as, for example, by dividing a dose of approximately 2080 μL intotwo approximately equal sized doses for example at steps (1001B and1004B) described above.

The foregoing description, for purposes of explanation, used specificnomenclature to provide a thorough understanding of the describedembodiments. However, it will be apparent to one skilled in the art thatmany of the specific details are not required in order to practice thedescribed embodiments. Thus, the foregoing descriptions of the specificembodiments described herein are presented for the purposes ofillustration and description. They are not targeted to be exhaustive orto limit the embodiments to the precise forms disclosed. It will beapparent to one of ordinary skill in the art that many modifications andvariations are possible in view of the above teachings.

The Summary and Abstract sections may set forth one or more but not allexemplary embodiments of the present invention as contemplated by theinventors, and thus, are not intended to limit the present invention andthe appended claims in any way.

The foregoing description of the specific embodiments will so fullyreveal the general nature of the invention that others can, by applyingknowledge within the skill of the art, readily modify and/or adapt forvarious applications such specific embodiments, without undueexperimentation, without departing from the general concept of thepresent invention. Therefore, such adaptations and modifications areintended to be within the meaning and range of equivalents of thedisclosed embodiments, based on the teaching and guidance presentedherein. It is to be understood that the phraseology or terminologyherein is for the purpose of description and not of limitation, suchthat the terminology or phraseology of the present specification is tobe interpreted by the skilled artisan in light of the teachings andguidance.

The packages of the present invention may be manufactured using knownmaterials and processes. The packaging materials may be virgin, recycledor a combination thereof. The volume within the package cavity can varydepending on the design selected.

Not all the features described herein need to be incorporated into everypackage, and those of skill in the art, using the teachings herein, cancombine the features to provide a wide variety of improved contact lenspackages. In summary, the contact lens packages of the present inventionincorporate several novel functionalities which may be combined in awide variety of combinations as described herein to provide the desiredimproved and/or single touch packaging. The breadth and scope of thepresent invention should not be limited by any of the above-describedexemplary embodiments but should be defined only in accordance with thefollowing claims and their equivalents.

What is claimed is:
 1. A contact lens package that houses a contact lensand packaging solution wherein the package is configured to lift thecontact lens out of the packaging solution when the package is squeezedby a user.
 2. The contact lens package of claim 1, wherein the packagecomprises a lever configured to hinge along a pivot line in a base ofthe package when a force is applied to the lever; and a lens supportconfigured such that the force applied to the lever causes the lenssupport to lift the contact lens out of the packaging solution.
 3. Thecontact lens package of claim 2, wherein the package is configured suchthat the force being applied to the lever causes the lens support tolift the contact lens out of the packaging solution in a position on thelens support capable of single-touch transfer by the user.
 4. Thecontact lens package of claim 2, wherein the lever is a discretecomponent that is coupled to the base by an attachment means.
 5. Thecontact lens package of claim 2, wherein the pivot line is defined by atleast one void in the base.
 6. The contact lens package of claim 2,wherein the pivot line is imparted into the base by one or more of: acrease, a cut, a thinned line, and an etch.
 7. The contact lens packageof claim 2, wherein the base is composed of a relatively rigid material.8. The contact lens package of claim 2, wherein the base and the lenssupport are a single unitary component.
 9. The contact lens package ofclaim 2, wherein the lever and the lens support are a single unitarycomponent.
 10. The contact lens package of claim 2, wherein the lenssupport is coupled to the base by at least one of: i) a laser weld; ii)heat; iii) an ultrasonic weld; and iv) an adhesive.
 11. The contact lenspackage of claim 2, wherein the base comprises at least one fingerengagement feature configured to i) aid a user in grasping the packageor i) direct the application of force such that the lever hingesdownward.
 12. The contact lens package of claim 11, wherein the at leastone finger engagement feature comprises a protrusion in the base at adistal end of the package.
 13. The contact lens package of claim 11,wherein the at least one finger engagement feature comprises an overhangalong at least a portion of the package's periphery.
 14. The contactlens package of claim 11, wherein the at least one finger engagementfeature comprises a dimple sized to accommodate a finger or thumb of theuser, wherein the dimple is positioned at an end of the base proximal tothe user.
 15. The contact lens package of claim 11, wherein the at leastone finger engagement feature comprises a proximal finger engagementfeature positioned at an end of the base proximal to the user and adistal finger engagement feature positioned at an end of the base distalto the user.
 16. The contact lens package of claim 2, wherein a lid ofthe package comprises a lens facing surface that extends downward intothe cavity above the contact lens when the package is in an unopenedstate.
 17. The contact lens package of claim 16, wherein the lens facingsurface and lens support are configured within the cavity such that theoptical zone of the contact lens is suspended in the packaging solutionbetween the lens facing surface and lens support when the package is inan unopened state.
 18. The contact lens package of claim 1, wherein thepackage houses the contact lens in a convex position when the package isin an unopened or opened state.
 19. The contact lens package of claim 2,wherein the lens support has a profile that does not substantially matchthe contact lens's profile.
 20. The contact lens package of claim 2,wherein when the package is an opened state the wetted contact areabetween the lens support and the contact lens is less than about 30 mm²,less than about 25 mm², or less than about 20 mm².
 21. The contact lenspackage of claim 2, comprising at least one lens facing surface in thecavity above a convex side of the contact lens, wherein when the packageis in an unopened state the at least one lens facing surface isconfigured to align the contact lens over the lens support; or protectthe contact lens against significant optical damage due togravitational, mechanical, or air-induced forces.
 22. The contact lenspackage of claim 2, comprising a lid insert, wherein the lid insert isattached to an inner surface of the lid.
 23. The contact lens package ofclaim 22, wherein the lid insert includes at least one alignmentfeature.
 24. The contact lens package of claim 22, wherein the lidinsert includes at least one lock-out feature.